C annondale D iagnostic Tool M anual For vehicles (ATV & Motorcycles) equipped with the MC1000 Engine Management System Software CD P/N 971-5001983 Data Cable P/N 971-5001984 DANGER POTENTIAL HAZARD Running the engine indoors. Breathing exhaust gases. WHAT CAN HAPPEN Running the engine indoors will expose you to dangerous exhaust gases. Breathing carbon monoxide gas leads to poisoning, asphyxiation, and death. This will happen rapidly and without notice. HOW TO AVOID THE HAZARD Never operate the vehicle indoors even for brief periods. Cannondale Diagnostic Tool Manual.fm © 2001 Cannondale Corporation - All Rights Reserved P/N 912-5001985 Printed : 11/8/01 S afety A lerts · · FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Keep this Assembly manual in a safe place. Messages with the Safety Alert Symbol · Pay special attention to all messages preceded by the Safety Alert Symbol. The Safety Alerts symbols means: ATTENTION! BECOME ALERT! YOUR and YOUR CUSTOMER'S SAFETY IS INVOLVED. Indicates that severe personal injury or death WILL result if instructions are not followed. DANGER WARNING Indicates a potential hazard that COULD result in serious injury or death. CAUTION Indicates a potential hazard that could result in vehicle damage if instructions are not followed. NOTE : Provides helpful information Cannondale Diagnostic Tool Manual.fm © 2001 Cannondale Corporation - All Rights Reserved 2 Basics WHAT IS THE CANNONDALE DIAGNOSTIC TOOL? The Cannondale Diagnostic Tool is a Windows-based software program and special data cable that enables you to connect and communicate with vehicles using the MC1000 Engine Management System. The software is installed on a PC or Pocket PC, then the PC (or Pocket PC) is connected to the vehicle wiring harness via the special data cable. Once the software is installed in the PC and communication with the vehicle ECU is established, here's what the tool can do: · · · · · Send a calibration file from the PC to the vehicle ECU. Receive a calibration file from the vehicle ECU to the PC. Set the vehicle throttle body and injector variables Monitor the (vehicle) ECU operating parameters Read system faults INSTALLING THE SOFTWARE To install the Cannondale Diagnostic Tool in your PC, insert the installation CD in your computer CDROM drive. Use the Windows explorer and open the program Setup.exe on the software CD. Follow the step-by-step instructions. When the installation is complete, go to the security set-up. See next heading. SECURITY SET_UP After the software has been installed on your PC, click on the Windows START button in the lower left corner of your desktop go to Cannondale DIagnostic and Maintenance Program group and open SecurityCode.exe. Follow the instructions that are displayed in program window. When the security code is entered (after you call Optimum Power to get it), you can begin using the software. ALWAYS MAKE SURE THE VEHICLE BATTERY IS FULLY CHARGED Before performing any diagnostic work on the vehicle make sure the battery is at full charge. If the battery voltage is low the ECU power relay may drop out and shut off the ECU. If the battery is not fully charged the ECU power relay can drop out while the engine is cranking over. Why? During crank over the battery voltage could drop below the needed latch voltage of 10 volts. ALWAYS MAKE SURE THE ECU IS POWERED-UP The vehicle's ECU operates on a relay controlled power source which is separate from any lighting or starting electrical systems. The relay "latches-in" the ECU when the crankshaft sensor detects flywheel movement. If the ECU senses inactivity (no engine start or communications between the PC and ECU) for two minutes, it powers down. If you try to communicate with the ECU when it is powered-down or off, the "Failed to Unlock System 125" message will display. POWERING-UP MOTO ECU'S On motorcycles, power-up is relatively simple. Press the green start button and release it without starting the engine. When the system is powered-up the green LED on the data cable "block" will light. 3 P/N 912-5001985 Printed : 11/8/01 POWERING-UP ATV ECU'S To power-up the ECU on ATVs you have to switch the ignition switch to the "ON" position, then switch the engine switch to the RUN position. Then, press the green start button and release it without starting the engine. When the system is powered-up the green LED on the data cable "block" will light. After 2 minutes of inactivity, the ECU will power-down automatically except with the ATV the data cable block green LED will not go out. It will remain lit as long as the ATV ignition is in the "ON" position. CONNECTING THE DATA CABLE 2 1 3 4 1. 2. 3. 4. Serial connector (female to PC) Serial connector (male to Pocket PC) LED Cable connector (to vehicle) 2 3 2 1 3 1 1. 2. 3. Motorcycle harness connector - on this model (2002 X440s) the connector is secured to the relay mounting plate on the frame spar. Components have been removed for this photo. Cap Data interface connector 1. 2. 3. ATV harness connector - located under the right front fender near the main fuse Cap Main fuse holder Cannondale Diagnostic Tool Manual.fm © 2001 Cannondale Corporation - All Rights Reserved 4 "FAILED TO UNLOCK SYSTEM 125". This message means that the Cannondale Diagnostic Tool was not able to communicate with the vehicle ECU. If you see this message check one or more of the following: · · · · · Make sure that both the vehicle harness connector and data cable are undamaged (pins not bent or broken) and the connectors are properly locked together. Make sure the vehicle battery is fully charged. Make sure the vehicle ECU is powered-up. See page 3. Make sure the data cable is plugged securely into the PC. Click OK and start again. 5 P/N 912-5001985 Printed : 11/8/01 MAIN SCREEN (1) 00200 (2) (3) (4) (5) (6) (7) (8) (9) (10) (5) (8) 00200 00200,X440s,082801 (1) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Calibration file identification Opens a saved calibration file Receives a calibration file from the vehicle's ECU Sends the current calibration file to the vehicle ECU Used to set the vehicle's throttle body (min./max. values) Used to monitor ECU parameters (rpm, throttle body offset, battery voltage, airbox temp, airbox temp, engine temp, IACV) Receives faults from the vehicle ECU Used to update throttle body leakage, fuel injector flow rate, injector offset Progress indicator Used to display Cannondale Diagnostic Tool version info Cannondale Diagnostic Tool Manual.fm © 2001 Cannondale Corporation - All Rights Reserved 6 1 - CALIBRATION FILE ID On the top left corner of the Cannondale Diagnostic Tool main screen there will be a Numeric Cal ID number for the calibration file that is open. If "Untitled" is displayed in this area of the screen, no calibration file has been opened (from a saved file) or received from the vehicle ECU. In addition to the ID number, each calibration file is assigned a 128-character description. Although Cannondale assigns a Numeric Cal ID and description to authorized files, a calibration file is like most other kinds of computer files. Its possible to changes to the Numeric Cal ID and description through third party software applications. Do not experiment with calibration files! Sending unidentified, altered, or third party calibration files can result in severe damage to the vehicle or affect the safe operation of the vehicle. You could be severely injured or killed in a resulting accident. Always consult the Cannondale website (www.cannondale.com) for calibration files authorized for a specific vehicle identification number (VIN). The ECU for each ATV and Motorcycle leaving the Cannondale factory is loaded with a specific calibration file. All calibration files developed by Cannondale are assigned a Numeric Cal ID code. Refer to "Numeric Cal ID Coding" starting on page 8. The code identifies the model, and sequence of the calibration file issued. The calibration files SHOULD NOT be interchanged between model VINs or models. A database of calibrations files is maintained on the Cannondale website so that service technicians have ready access to the correct factory authorized calibration files for a particular vehicle VIN. Vehicle's equipped with a third party (aftermarket) map select interface can toggle maps (and other fueling features) while the engine is running to meet changing performance demands. 7 P/N 912-5001985 Printed : 11/8/01 NUMERIC CAL ID CODING MODEL CODE (2 DIGIT) 0 0 YEAR 0 SEQ (2 DIGIT) 00 thru 99 MODEL CODES Code 0 0 0 0 3 3 3 3 0 1 2 3 0 1 2 3 Model X440s X440 C440 E440 Cannibal Speed Blaze Moto 440 YEAR Year 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 Code 2 3 4 5 6 7 8 9 0 1 NOTE : Reset every 10 years SEQ 00 thru 99 NOTE : The two digit SEQ number is assigned sequentially. When a calibration file is updated the SEQ number increases. However, due to continual product evolution, the updated calibration file for the model may not be authorized for use in vehicles produced previously. Always consult the Cannondale website for the compatibility of calibration files for a specific vehicle VIN number. Cannondale Diagnostic Tool Manual.fm © 2001 Cannondale Corporation - All Rights Reserved 8 2 - OPENING A CALIBRATION FILE The OPEN Calibration File (saved) button opens the Windows explorer so that you can look for and open a calibration file that is saved on your PC or Pocket PC. A saved calibration file might be one that you have received via e-mail, downloaded from the Cannondale website, or one that is stored on a diskette or CD. This button functions the same way as if you click File - Open. 3 - RECEIVING A CALIBRATION FILE FROM THE VEHICLE ECU The RECEIVE Calibration File (from ECU) button allow you to receives the calibration file from the vehicle's ECU to the Cannondale Diagnostic Tool. It works just like opening a saved calibration file, but unlike opening a saved calibration file on your computer the calibration file will be "received" from the vehicle ECU across the data cable. NOTE : The received calibration file is not removed from the ECU, it is merely copied into the Cannondale DiagnosticTool program. 1. Connect the data cable to the computer and vehicle. 2. Open the Cannondale Diagnostic Tool software on your PC. 3. Power-up the vehicle's ECU. 4. Click the RECEIVE Calibration File (from ECU) button. After you click the button, the data transfer will start. While the data is copied from the ECU to the PC the progress indicator in the upper right of the menu will display and the LED on the data cable block may appear to flicker. The time required for the transfer could vary. It should take place within 1 minute. When the entire data transfer process is complete, you will see the "Receive complete" message. 5. Click OK. The vehicle calibration file has now been copied to the Cannondale Diagnostic Tool program. 9 P/N 912-5001985 Printed : 11/8/01 4-SEND CALIBRATION FILE (TO ECU) The SEND Calibration File (to ECU) button "sends" the calibration file open (in the Cannondale Diagnostic Tool software) to the vehicle ECU. Whenever you send a calibration file to the vehicle ECU you have to keep the following points in mind: · The software will automatically retrieve the vehicle specific variables (throttle positions (min./max), throttle body offset, injector flow rate, injector offset) from the vehicle's current calibration file (if specific values have not been entered manually) and send the retrieved values with the open file. The process is automatic. Anytime the throttle body is serviced, you will have to reset or "teach" the ECU the new values before the new calibration file is sent to the ECU. In the case of a replaced throttle body or injector set, you will have to enter the throttle body offset and injector flow rate, and injector offset variable values that are supplied with the components in the main screen before sending the calibration file to the vehicle. Refer to "8 - Updating calibrations" starting on pa ge15. 1. Connect the data cable to the computer and vehicle. 2. Open the Cannondale Diagnostic Tool software on your PC. 3. Power-up the vehicle. When the vehicle is powered-up, the LED on the data cable block with be lit. 4. Open a calibration file or receive a calibration. 5. Click the SEND Calibration File (to ECU) button. The file that is open will be sent to the vehicle ECU. It will over-write the current calibration file stored in the ECU. When the send has been completed the vehicle ECU will automatically power itself down. The LED on the data cable block will turn off indicating the ECU power is now off. The calibration file just sent will remain "open" in the Cannondale Diagnostic Tool software program until the program is exited or another calibration file is opened or received. · Cannondale Diagnostic Tool Manual.fm © 2001 Cannondale ...